Land Rover Defender 300tdi Workshop 3rd Edition Rover Manual

37MANUAL GEARBOX
4
REPAIR
37.Pull handbrake cable through heel board and tie
aside.
38.Remove retaining nut, release clamp, and
disconnect speedometer cable from transfer box.
39.Release speedometer cable from retaining clip
on transfer box.
40.Remove retaining nut and release battery earth
strap from transfer box.
41.Secure manufactured cradleLRT-99-007to a
suitable hydraulic hoist.
42.Raise hoist and secure to gearbox with 3 bolts in
location provided.
43.Lower hoist sufficiently to allow transfer...

MANUAL GEARBOX
5
REPAIR Separating transfer gearbox from main gearbox
50.Remove transmission assembly from hoist
cradle and position safely on a bench.
51.Remove breather pipes. Discard pipe union
sealing washers.
52.Remove Nyloc nut, and remove bolt, securing
lever to high/low shaft.
53.Collect spacer washer.
54.Remove 2 clips and remove differential lock
lever link.
55.Remove lower locknut from high/low operating
rod.
56.Place a sling round transfer box and attach to
hoist.
57.Remove nut and 4 bolts...

37MANUAL GEARBOX
6
REPAIRREV: 05/99 78.Position crossmember and locate over fixing
studs of LH and RH gearbox mounting rubbers.
79.Align crossmember and secure to chassis with 4
nuts and bolts on each side.
NOTE: Fit battery earth strap retaining clip
to LH top bolt.
80.Fit intermediate silencer.
See MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
pipe - 90
orSee MANIFOLD AND EXHAUST
SYSTEM, Repair, Intermediate pipe - 110/130
.
81.Fit front pipe to exhaust manifold
See
MANIFOLD AND EXHAUST SYSTEM,...

MANUAL GEARBOX
1
SPECIFICATIONS, TORQUE REV: 05/99 TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Slave cylinder to bell housing 25....................................................................
Breather 15.....................................................................................................
Bell housing to cylinder block...

TRANSFER GEARBOX
1
DESCRIPTION AND OPERATION TRANSFER GEARBOX
Description
The transfer gearbox is a permanent 4 wheel drive,
two speed ratio reducing gearbox, incorporating high
and low range outputs with mechanically lockable
centre differential (diff-lock). High/low range and
diff-lock selection are made via a single lever located
forward of the main gear lever.
The transfer gearbox is mounted at the rear of the
main gearbox, the mainshaft of which extends into the
transfer casing. A transfer gear,...

TRANSFER GEARBOX
1
FAULT DIAGNOSIS TRANSFER GEARBOX - OIL SEAL LOCATIONS
1.Input seal.
2.Cover plate joints.
3.Front output seal.
4.Front and rear housing joint faces.5.Rear output seal.
6.Power take off cover plate joint.
7.Bearing plate joint. 

41TRANSFER GEARBOX
2
FAULT DIAGNOSIS OIL LEAKS
Verify that oil leak is from transfer box and not main
gearbox before proceeding with checks.
Prior to road test
1.Check oil level in transfer box is correct.
2.Check tightness of level and drain plugs.
3.Check breather system for blockage. To validate
system pipe must be removed, inspected,
rectified as necessary and refitted.
4.Remove all traces of oil from exterior of transfer
box.
Take vehicle for short road test.
5.Identify source of leaks and rectify...

TRANSFER GEARBOX
1
REPAIR TRANSFER GEARBOX
Service repair no - 41.20.25
Remove
The transfer gearbox should be removed from
underneath the vehicle, using a hydraulic hoist and
adaptor plateLRT-99-010.
WARNING: Where use of a transmission
hoist is necessary, it is absolutely
essential to follow the manufacturers
instructions to ensure safe and effective use of
the equipment.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and...

41TRANSFER GEARBOX
2
REPAIR
11.Remove 3 trim studs and lift up handbrake
gaiter.
12.Remove split pin, clevis pin, washer and
disconnect cable from handbrake lever. Ensure
handbrake is off.
13.Release handbrake outer cable from heelboard.
14.Remove fan cowl
See COOLING SYSTEM,
Repair, Fan cowl
.
15.Raise vehicle on ramp.
16.Drain transfer box oil
See SECTION 10,
Maintenance, Under vehicle maintenance
.
17.Remove intermediate silencer.
See MANIFOLD
AND EXHAUST SYSTEM, Repair,
Intermediate pipe - 90
orSee...

TRANSFER GEARBOX
3
REPAIR 23.Position 4, 30 mm (1.25 in), spacers between
top of hoist and adaptor plate,LRT-99-010,at
securing points and secure adaptor plate to
hoist.
24.Remove 4 central bolts from transfer box bottom
cover, move hoist into position and secure
adaptor plate to transfer box.
25.Adjust hoist to take weight of transfer box.
26.Remove nut securing transfer box LH mounting
rubber to chassis crossmember.
27.Remove 4 nuts and bolts securing chassis
crossmember to chassis longitudinal....